Method of forming a tampon having a resilient member

ABSTRACT

A method of forming a catamenial tampon is disclosed wherein the tampon is useful in preventing premature leakage of body fluid from a woman&#39;s vagina and in providing better utilization of the absorbent during use. The method includes the steps of assembling a resilient member and an absorbent to form a structure having a central longitudinal axis X—X. The resilient member can be either aligned with or offset from the central longitudinal axis X—X. The absorbent and the resilient member are rolled or folded up into an elongated softwind which has a first end and a second end. The softwind is folded upon itself such that the first and second ends are aligned adjacent to one another and the softwind contains at least two folds therebetween. The softwind is then compressed into a pledget having an insertion end and a trailing end. A withdrawal string is secured to the pledget to form a tampon. The withdrawal string facilitates removal of the tampon from the woman&#39;s vagina.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation of application Ser. No. 09/035,723, filed Mar. 5,1998, issued Mar. 21, 2000, as U.S. Pat. No. 6,039,828; which is adivision of application Ser. No. 08/693,686, filed Aug. 12, 1996, nowU.S. Pat. No. 5,755,906.

FIELD OF THE INVENTION

This invention relates to a method of forming a tampon having aresilient member. More specifically, this invention relates to a methodof forming a catamenial tampon having a resilient member which isdesigned to prevent premature leakage of body fluid from a woman'svagina when the tampon is initially inserted into the woman's vagina andto provide better utilization of the absorbent during use.

BACKGROUND OF THE INVENTION

Currently, there are two basic types of catamenial tampons used forfeminine hygiene. The first type is a digital tampon which is designedto be inserted into a woman's vagina directly by the user's fingers. Thesecond type is a tampon which is designed to be inserted with the aid ofan applicator. Both types are usually made by folding or rolling aloosely associated strip of absorbent material into an elongated shapeoften referred to as a “softwind.” The softwind is then radially and/orbiaxially compressed into a pledget. The pledget may or may not includea cover. In both types of tampons, a withdrawal string is attached tothe absorbent, either before or after compression, to facilitate removalof the tampon from the user's vagina after it has absorbed a certainquantity of body fluid, such as menses, blood, etc.

It has been found that many tampons, both digital as well as thosedelivered by an applicator, are unable to prevent premature leakage ofbody fluid. Premature leakage can result from a number of factors. Onefactor is that the tampon does not properly fit above the introitalregion of the vagina. A second factor is that the tampon has beencompressed to such an extent that it is unable to open or radiallyexpand rapidly enough after initial insertion into a woman's vagina toabsorb the body fluid which comes into contact with it. A third factoris that the tampon is not shaped correctly to intercept fluid flowthrough the vaginal canal. A fourth factor is that the folds andconvolutions of the vagina are not all in contact with the tampon andtherefore body fluid is able to bypass the tampon.

Now a method of forming a catamenial tampon has been invented. Themethod includes forming a tampon having a resilient feature which willprevent premature leakage of body fluid immediately after being insertedinto a woman's vagina and provide better utilization of the absorbentduring use.

SUMMARY OF THE INVENTION

Briefly, this invention relates to a method of forming a catamenialtampon. The method includes the steps of assembling a resilient memberand an absorbent to form a structure having a central longitudinal axisX—X The resilient member can either be aligned with or offset from thecentral longitudinal axis X—X. The absorbent and the resilient memberare then rolled or folded up into an elongated softwind which has afirst end and a second end. The elongated softwind is then folded suchthat the first and second ends are aligned adjacent one another and thesoftwind contains at least two folds therebetween. The softwind is thencompressed into a pledget having an insertion end and a trailing end. Awithdrawal string is then secured to pledget to form a tampon. Thewithdrawal string facilitates removal of the tampon from a woman'svagina.

The general object of this invention is to provide a method of forming atampon for the absorption of menses, blood, etc. A more specific objectof this invention is to provide a method of forming a catamenial tamponhaving a resilient feature which is designed to prevent prematureleakage of body fluid when initially inserted into a woman's vagina andprovide better utilization of the absorbent during use.

Another object of this invention is to provide a method of forming atampon which springs open immediately upon insertion into a woman'svagina to prevent bypass of menses and other body fluids.

A further object of this invention is to provide a method of forming atampon which contains a resilient member which has the potential to openat least a portion of the tampon so that the tampon will contact alarger cross-section of a woman's vagina, thereby preventing thepremature leakage of body fluid.

Still another object of this invention is to provide a method of forminga tampon which has wet and dry expansion capability.

Still further, an object of this invention is to provide a method offorming a tampon which exhibits reduced slippage during use.

Still further, an object of this invention is to provide a method offorming a tampon which is expandable to fit within the non-circularcross-section of a woman's vagina.

Still further, an object of this invention is to provide a method offorming a tampon with better utilization of the absorbent during use.

Other objects and advantages of the present invention will become moreapparent to those skilled in the art in view of the followingdescription and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a resilient member positioned on anabsorbent and aligned along the central longitudinal axis X—X thereof.

FIG. 2 is a perspective view of the absorbent and. resilient membershown in FIG. 1 after being rolled or folded into a softwind.

FIG. 3 is a perspective view of an alternative embodiment depicting anabsorbent cover and resilient member being aligned such that theresilient member is offset from the central longitudinal axis X—X.

FIG. 4 is a perspective view of the absorbent, cover and resilientmember shown in FIG. 3 rolled up into a softwind.

FIG. 5 is a side view of the softwind folded into a generally M-shapedprofile with the first and second ends being aligned adjacent to oneanother and retained by the withdrawal string.

FIG. 6 is a side view of the softwind shown in FIG. 5 after it has beencompressed into a pledget.

FIG. 7 is a side view of the tampon showing the configuration itattempts to acquire after it has been inserted into a woman's vagina.

FIG. 8 is a side view of the tampon showing one possible configurationduring removal from a woman's vagina.

FIG. 9 is a side view of a two piece tampon applicator having an innertube and an outer tube.

FIG. 10 is a cross-sectional view of the tampon applicator shown in FIG.9 depicting the tampon being retained in the outer tube prior toinsertion into a woman's vagina.

FIG. 11 is a flow diagram of a method of forming a tampon.

FIG. 12 is a flow diagram of an alternative method of forming a tampon.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, one possible way of forming a catamenial tampon 10is shown which is useful for absorbing body fluid from a woman's vagina,especially during her menstrual cycle. The tampon 10 is designed to beinserted above the introital region of a woman's vagina and is designedto function so as to intercept the fluid flow of menses, blood, andother body fluids and prevent the fluid from exiting the vagina. Thetampon 10 includes an absorbent 12 which may contain a cover 14. Theabsorbent 12 can be formed from absorbent fibers which are assembledinto an absorbent sheet or ribbon. Alternatively, the absorbent 12 canbe formed from absorbent fibers which are assembled and compressed intoa generally elongated and/or cylindrical configuration. The absorbent 12is preferably formed from cellulosic fibers, such as cotton and rayon.The absorbent can be 100% cotton, 100% rayon, or a blend of cotton andrayon fibers. Some blends which have been tried and work well include ablend of about 15% cotton to about 85% rayon; about 70% cotton to about30% rayon; about 60% cotton to about 40% rayon; about 25% cotton toabout 75% rayon; and about 6% cotton to about 94% rayon. The particularblend of fibers can vary depending upon one's preference.

When cotton fibers are used, the cotton fibers should have a staplelength of between about 5 millimeters (mm) to about 20. The cottonfibers should generally have a fiber size of between about 150 micronsto about 280 microns. The cotton fibers can also be bleached if desired.Bleaching will make the cotton fibers whiter in appearance.

When rayon fibers are present, the rayon fibers should have a staplelength of between about 20 mm to about 35 mm. The rayon fibers shouldhave a denier of between about 2 to about 6. Denier is a unit offineness of yam based on a standard of 50 milligrams (mg) for 450 metersof yam. The rayon fibers can have a circular, a bi-lobal, a tri-lobalcross-sectional configuration, or some other cross-sectionalconfiguration known to those skilled in the art The bi-lobalconfiguration has a cross-sectional profile which looks like a dog bonewhile the tri-lobal configuration has a cross-sectional profile whichlooks like a “Y”. The rayon fibers can also be bleached if desired.

The absorbent 12, when formed from an absorbent sheet or ribbon, isconstructed from a blend of cotton and rayon fibers. Two processes forforming such an absorbent sheet are known as “carding” and “airlaying”.Depending upon the desired absorbency one desires in the finishedtampon, the basis weight of the absorbent sheet can vary. The U.S. Foodand Drug Administration (FDA) has set absorbency standards for “junior”,“regular”, “super” and “super-plus” size tampons. In order to meet theFDA standards for these four sizes, the absorbent sheets are targeted tohave basis weights of about 100 grams per square meter (gsm), 120 gsm,170 gsm and 230 gsm, respectively. Typically, the carding process iscontrolled to produce an absorbent sheet with a width of between about40 mm to about 60 mm, preferably about 50 mm. The basis weight and/orthe length of the absorbent 12 can also be adjusted to form thedifferent size tampons.

The absorbent 12 can be partially or fully enclosed by a cover 14,preferably a liquid permeable cover. By “liquid-permeable” it is meantthat body fluid is able to pass through the cover 14 in a quick andefficient manner. The cover 14 can be hydrophilic or hydrophobic. By“hydrophilic” it is meant that the cover 14 has an affinity forabsorbing or tending to combine with water. By “hydrophobic” it is meantthe cover 14 is antagonistic to or tending not to combine with water.The cover 14 can also be treated with a surfactant or other material tomake it hydrophilic or to make it more hydrophilic.

The liquid-permeable cover 14 can be formed from woven or nonwovenmaterials having a porous substrate. Woven materials include textilefabrics which can be made from rayon, cotton or polyolefins. Thepolyolefins can be either staple or continuous filaments. The nonwovenmaterials can include spunbond, bonded carded webs and hydroentangledwebs. Spunbond and bonded carded webs are commercially sold byKimberly-Clark Corporation having an office at 401 N. Lake Street,Neenah, Wis. 54956. Another nonwoven material which can be used as thecover 14 is formed from 100% polyester fibers held together by a binder.This material is known as powder-bonded-carded web (PBCW). PBCW iscommercially available from HDK Industries, Inc. having an office at 304Arcadia Drive, Greenville, S.C. 29609. The cover 14 can further beformed from an apertured thermoplastic film having either atwo-dimensional or a three-dimensional thickness. Aperturedthermoplastic films are available from several commercial vendors. Twosuch vendors include Pantex Srf, Pantex Sud srf, Via Terracini snc,having an office at 51031 Agliana, Pistoia, Italy and Applied ExtrusionTechnology having a mailing address of P.O. Box 582, Middleton, Del.19709.

The liquid-permeable cover 14 can be treated with an aqueous solution toreduce frictional drag, to give the tampon 10 a permanent wettabilityand to enhance the ease of insertion into and withdrawal from a woman'svagina. The cover 14 can be treated either before being rolled or foldedup with the absorbent 12 and a resilient member 16 or after a softwind18 has been formed. The different types of aqueous solutions which canbe used are known to those skilled in the art. One particular type ofaqueous solution is taught in U.S. Ser. No. 08/311,692, filed Sep. 23,1994 and entitled: “TAMPON EXHIBITING LOW FRICTIONAL DRAG.” This patentapplication is assigned to Kimberly-Clark Corporation and isincorporated by reference and made a part hereof.

The tampon 10 further includes a resilient member 16 which is positionedon the top surface of the absorbent 12. The three vertically stackedmembers, from top to bottom, include the resilient member 16, theabsorbent 12 and the liquid-permeable cover 14. The three members areshown having a rectangular configuration and being symmetrically alignedrelative to a central longitudinal axis X—X. It should be noted that theabsorbent 12 and cover 14 could have different configurations ifdesired, for example, an hourglass configuration. The resilient member16 should be capable of having what is known as “dry and wet expansion”characteristics. In other words, the resilient member 16 should be madeof a material which is capable of expanding back to or towards itsoriginal configuration in either a dry state, a wet state, andpreferably, in both a dry and a wet state. Dry expansion of theresilient member 16 is beneficial in that the tampon 10 does not have tobe wetted by body fluid before the resilient member 16 is capable ofexpanding. Furthermore, it is advantageous to employ a material for theresilient member 16 which is capable of expanding even while the tampon10 is wetted by body fluid. For purposes of this invention, theresilient member 16 can be a resilient foam, such as a closed cell foamor an open cell foam. Other materials from which the resilient member 16can be made from include polyethylene oxide (PEO) and polyvinyl alcohol(PVA). The resilient member 16 can also be formed from resilient fiberssuch as polyolefin based fibers, polyethylene oxide fibers, hydrophobicrayon fibers and the like which preferably will have characteristicssimilar to those of a resilient foam. The resilient member 16 can alsobe made or constructed from a wettable foam. An open cell foam whichworks well and has good resilient properties is commercially availableunder the trade name ACQUELL and is sold by Sentinel ProductsCorporation having an office located at 70 Airport Road, Hyannis, Mass.02601. A polyethylene closed cell foam having good flexibilitycharacteristics also works well. This foam is commercially sold underthe tradename “VOLARA” and is available from Voltex, a Division ofSekisui America Corporation, having an office located at 100 ShepardStreet, Lawrence, Mass. 01843.

The resilient member 16 can have a square, rectangular, oval, circular,or any other desired cross-sectional configuration. Preferably, theresilient member 16 will have a uniform thickness and width. If desired,the dimensions of the resilient member 16 do not have to have uniform.As depicted in FIG. 1, the resilient member 16 has a length L₁ which isless than the length L₂ of the absorbent 12. The width W₁ of theresilient member 16 is less than the width W₂ of the absorbent 12. Ithas been found that a resilient member 16 having a length of betweenabout 1 inch to about 5 inches (about 25.4 mm to about 127 mm), a widthW₁ of between about 0.25 inches to about 0.50 inches (about 6.3 mm toabout 12.7 mm), and a height H₁ of between about {fraction (1/16)} of aninch to about ⅛ of an inch (about 1.6 mm to about 3.2 mm) works wellwhen positioned on an absorbent 12 having a length L₂ of from betweenabout 3 inches to about 10 inches (about 76 mm to about 254 mm), a widthW₂ of from between about 1 inch to about 3 inches (about 25.4 mm toabout 76 mm), and a height H₂ of from between about ⅛ of an inch toabout 1 inch (about 3.2 mm to about 25.4 mm).

The resilient member 16 can have a length L₁ which is only a fraction ofthe length L₂ of the absorbent 12. Alternatively, the resilient member16 can have a length L₁ which is equal to the length L₂ of the absorbent12. In FIG. 1, the resilient member 16 is shown having a length L₁ whichis equal to about ½ of the length L₂ of the absorbent 12. It should benoted that the resilient member 16 should have a length L₁ which is atleast ⅓ of the length L₂ of the absorbent ribbon 12, and preferably, atleast ½ of the length L₂ of the absorbent 12. Alternatively, theresilient member 16 or 16′ can have a length L₁ which is equal to orapproximately equal to the length L₂ of the absorbent 12, as is depictedin FIG. 3.

Referring to FIG. 2, the absorbent 12, the cover 14 and the resilientmember 16 are shown after they have been rolled or folded into agenerally elongated member often referred to as a “softwind” 18. Thesoftwind 18 has a central longitudinal axis X—X and is an elongated,tubular shaped member. The softwind 18 can have a circular, square,rectangular or other cross-sectional profile but preferably is elongatedand has a cylindrical shape. The softwind 18 can have a length of up toabout 10 inches (about 254 mm). Preferably, the softwind 18 has a lengthof from between about 2 inches to about 8 inches (about 51 mm to about203 mm), and most preferably, it has a length of about 6 inches (about152 mm). The length of the softwind can be varied so as to obtain thevarious size tampons.

When the softwind 18 has a circular cross-section, it can have adiameter ranging from between about 0.5 inches to about 2 inches (about12.7 mm to about 51 mm), and preferably, will have a diameter of about 1inch (about 25.4 mm). The specific diameter of the softwind 18 will bedictated by the type of tampon which is to be formed, such as a“junior”, “regular”, “super”, or “super-plus” size tampon. The softwind18 is not compressed.

When the absorbent 12. the cover 14 and the resilient member 16 arerolled into the softwind 18, the cover 14 can have a width W₃ which isequal to or greater than the width W₂ of the absorbent 12. A wider widthfor the cover 14 is preferred for it enables the cover 14 to be wrappedaround the exterior surface of the absorbent 12 and overlap upon itself,as indicated at 20. If the width W₃ of the cover 14 is equal to thewidth W₂ of the absorbent 12 then the ends of the cover 14 will abut oneanother. The overlap design for the cover 14 is preferred.

Referring again to FIG. 2, the absorbent 12, the cover 14 and theresilient member 16 are rolled up or folded into the softwind 18 whichhas a first end 22 and a second end 24. The first and second ends, 22and 24 respectively, are spaced apart from each other. Since theresilient member 16 is spaced inward from the first and second ends, 22and 24 respectively, the resilient member 16 is not visible when thesoftwind 18 is formed. In forming the softwind 18, the cover 14 isdepicted as being overlapped upon itself at 20 and can be bonded toitself and/or to the absorbent 12. It should be again mentioned that ifthe softwind 18 can be formed from the absorbent 12 alone, no cover 14need be present The cover 14 can be bonded using heat, pressure, heatand pressure, ultrasonics, an adhesive such as glue, or any other knownbonding technique. Alternatively, the cover 14 could be sprayed onto theabsorbent 12. The softwind 18 will have an length L₂ which will be equalto the length L₂ of the absorbent 12 and the cover 14. Should the cover14 have a longer length than the absorbent 12, then the softwind 18would have a length equal to the cover 14, unless the ends of the cover14 are tucked at each end. The length of the cover 14 could also be lessthan L₂ to allow for cover drift during manufacture of the softwind 18.

Referring to FIGS. 3 and 4, an alternative embodiment is shown wherein atampon 10′ is formed by positioning a rectangular sheet of an absorbent12 over a rectangular sheet of a liquid-permeable cover 14 and thenpositioning a resilient member 16′ on the upper surface of the absorbent12. The absorbent 12 and the cover 14 both have an equal length L₂ whichis equal to the length of the resilient member 16′. The absorbent 12 hasa width W₂ which is slightly smaller than the width W₃ of the cover 14.The resilient member 16′ is offset from the central longitudinal axisX—X such that it is located adjacent to an outside edge of the absorbent12. In this configuration, it is easier to roll up the absorbent 12, thecover 14 and the resilient member 16′ to form an elongated generallycylindrically shaped softwind 18′. This embodiment also shows that theresilient member 16′ extends from the first end 22 to the second end 24of the softwind 18′. In this design, the resilient member 16′ is visibleat each end 22 and 24 of the softwind 18′. This configuration may beadvantageous in that the resilient member 16′ may be able to outwardlyexpand the tampon 10′ more fully when the tampon 10′ is initiallyinserted into the woman's vagina. The extra length of the resilientmember 16′ may allow for a more positive expansion. This embodiment mayalso be better at preventing or reducing slippage of the tampon 10′after it has been inserted above the introital region of a woman'svagina, thereby providing superior leakage protection. Another attributeof this embodiment is that the resilient member 16′ may only have tohave a portion of the resilient characteristic exhibited by the shorterresilient member 16. Comfort to the consumer can thereby be enhanced byusing a resilient member 16′ which does not have as much strength incausing the tampon 10′ to expand outward and span across the walls of awoman's vagina.

Referring to FIG. 5, the softwind 18 is folded or bent upon itself suchthat the first and second ends, 22 and, 24 respectively, are alignedadjacent to one another and the softwind 18 contains at least two folds26 and 28 located therebetween. By being aligned “adjacent to oneanother” it is meant that the first and second ends, 22 and 24respectively, are positioned side by side, parallel to one another,offset axially or spaced radially apart from one another, or arepositioned in some other type of arrangement whereby the first andsecond ends, 22 and 24 respectively, are close to one another.Preferably, the softwind 18 will contain three folds 26, 28 and 30 whichare located between the first and second ends, 22 and 24 respectively,to give the softwind 18 a generally M-shaped profile. In the generallyM-shaped profile, the softwind 18 is folded at 26 to form a firstportion 32 and is folded a second time at 28 to form a second portion 34and a third portion 36. The first and third portions, 32 and 36respectively, preferably have approximately the same length, althoughtheir lengths can differ as desired. It is also possible to form thefirst, second and third portions 32, 34 and 36 to have approximately thesame length. For example, if the softwind 18 has a length of about 6inches (about 152 mm), each of the portions 32, 34 and 36 can have alength of approximately 2 inches (about 51 mm). The resilient member 16should have a length such that it can extend between the first andsecond folds, 26 and 28 respectively. Preferably, the resilient member16 will extend along the length of the second portion 34 and will have asufficient length such that it will extend beyond the first and secondfolds, 26 and 28 respectively. It has been found that when the resilientmember 16 extends beyond the folds 26 and 28 by at least an ⅛ of an inch(about 3.2 mm), and preferably, by at least a ¼ of an inch (about 6.4mm), that the resilient member 16 becomes more effective in causing thesecond portion 34 to span laterally outward once the tampon 10 isinserted into a woman's vagina.

Referring again to FIG. 5, the third fold 30 provides the softwind 18with the generally M-shaped profile. The third fold 30 can be positionedan equal or an unequal distance between the first and second folds, 26and 28 respectively. When the third fold 30 is positioned an equaldistance between the first and second folds, 26 and 28 respectively, thethird fold 30 will be axially aligned along a central longitudinal axisY—Y, as is shown in FIG. 5. The central longitudinal axis Y—Y verticallydivides the generally M-shaped profile of the softwind 18 into left andright mirror images. It is also possible to form the third fold 30 doserto either the first or second folds, 26 and 28 respectively, if desired.The third fold 30 causes the second portion 34 of the resilient member16 to be folded into two parts such that a V-shape is obtained for thesecond portion 34.

The tampon 10 further includes a withdrawal string 38 for assisting inremoving the tampon 10 from the woman's vagina. The withdrawal string 38is attached to the absorbent 12, and preferably, to the first and secondends, 22 and 24 respectively, of the softwind 18. One method ofattaching the withdrawal string 38 is to form an aperture or hole 40through the first and third portions 32 and 36, approximate the firstand second ends, 22 and 24 respectively. The withdrawal string 38 isthen threaded through the aperture 40 and looped upon itself so as tocinch it secure to the absorbent 12. The free ends of the withdrawalstring 38 are then tied in a knot 42 to assure that the withdrawalstring 38 will not separate from the softwind 18. The knot 42 alsoserves to prevent fraying of the withdrawal string 38 and to provide aplace or point where a woman can grasp the withdrawal string 38 when sheis ready to remove the tampon 10 from her vagina. It should be notedthat the withdrawal string 38 holds the first and second ends, 22 and 24respectively, in direct contact with one another and will limit theamount they can expand while positioned within the woman's vagina. Itshould be noted that the withdrawal string 38 can be secured to and/orattached to various areas of the softwind 18 and can pass through eitherthe absorbent 12, the cover 14 or both. The withdrawal string 38 canalso be attached either before the softwind 18 is compressed or afterthe softwind 18 is compressed.

The withdrawal string 38 can be constructed from various types ofthreads or ribbons. A thread or ribbon made from 100 percent cottonfibers works well. The withdrawal string 38 should have a length whichextends beyond the end of the tampon 10 from between about 2 inches toabout 8 inches (about 51 mm to about 203 mm), preferably from about 4inches to about 6 inches (about 102 mm to 152 mm), and most preferably,about 5 inches (about 127 mm). The withdrawal string 38 can be dyedand/or treated with an anti-wicking agent, such as wax, before beingsecured to the softwind 18. The anti-wicking wicking agent willfacilitate and prevent body fluids from wicking along the withdrawalstring 38 and contacting the inner surface of a woman's undergarment. Adry, dean withdrawal string 38 is preferred by the user, especially whenshe goes to remove the tampon 10 from her vagina.

Referring to FIG. 6, the softwind 18 is compressed into a pledget 44having an insertion end 46 and a trailing end 48. The pledget 44 canhave any desired shape but preferably, it will have a generallycylindrically-shape with a circular cross-section configuration or agenerally elongated shape with a rectangular cross-sectionalconfiguration. The insertion end 46 is designed to be the first part ofthe pledget 44 which enters the woman's vaginal cavity. It should benoted that, while in use, the pledget 44 will be entirely positionedwithin the woman's vagina. The insertion end 46 contains a cleft 50formed by the fold 30. Because the softwind 18 has a generally M-shapedprofile, the insertion end 46 can contain an equal amount and,preferably, a greater amount of absorbent material than the trailing end48. When a greater amount of absorbent material is present at theinsertion end 46 and the outside diameter of the insertion end 46 isapproximately equal to the outside diameter of the trailing end 48, theamount of absorbent material in the insertion end 46 will have to bedensified to a greater extent than the absorbent material making up thetrailing end 48. By having a greater amount of absorbent materialpresent at the insertion end 46, the tampon 10 is better able to absorbbody fluid and prevent premature leakage. When the pledget 44 is formed,the absorbent 12, the cover 14 and the resilient member 16 are allcompressed. However, the compression step should not detrimentallyeffect the function of the resilient member 16. In other words, theresilient member 16 has to be capable of expanding outward towards or toits original configuration once the tampon 10 or 10′ is inserted intothe woman's vagina.

Referring to FIG. 7, the tampon 10 is shown in its expanded conditionwhich occurs immediately upon its insertion into a woman's vagina. InFIG. 7, one can see that the resilient member 16 has expanded the secondportion 34 such that the third fold 30 has disappeared and the first andthird portions, 32 and 36 respectively, are forced outwardly towards theinterior walls of the woman's vagina. The resilient member 16 is capableof expanding laterally outward towards its original position such thatat least a portion of the tampon 10 is expanded outward to interceptfluid flow through the woman's vagina. In the expanded condition, thetampon 10 will take on a generally triangular shape which is closed atthe bottom or trailing end 48 by the attachment of the withdrawal string38.

While within the vaginal cavity, the resilient member 16 will expandthereby causing the first and third portions, 32 and 36 respectively, tospring or expand outward and spread across the vaginal opening. Thetampon 10 will usually be positioned below the cervix and thereforeshould be in a position to capture any menses, blood, and/or mucus-likeclots discharged by the woman's body. The resilient, elastic andflexible characteristics of the resilient member 16 enables it torecover quickly from its compressed and deformed shape. This allows thetampon 10 to conform more ideally to the vaginal opening and pressagainst the inside walls and convolution of a woman's vagina. Thisaction will prevent the premature leakage of body fluid due to improperfit or the inability of the absorbent material of the tampon 10 toexpand outward rapidly enough to catch any body fluid which mayinitially contact the tampon 10. This tampon design will also providebetter utilization of the absorbent 12 during use.

The resilient member 16 also serves to reduce and/or prevent slippage ofthe tampon 10 within the vaginal canal. The vaginal canal is normally ina position of collapse in its lower portion for ¾ to ⅘ of its length.The lower ⅓ is essentially always closed and its inside walls arealigned side by side or next to each other as a result of the action ofthe muscular tissue of the vagina. As soon as the tampon 10 is insertedbeyond the lower portion of the vaginal canal, the muscular tissuecauses the inside walls to close off the vaginal mouth so that thetampon 10 can rest above this lower portion of the vagina. It willtherefore be self-evident that the tampon 10 cannot be dislodged throughmovement of the wearer's body. This is an important feature of thisinvention.

Referring again to FIG. 7, one can see that the resilient member 16 isstrong enough to cause the absorbent 12 to straighten out in the areawhere the third fold 30 was present. Preferably, the second portion 34will straighten out towards its original profile and the third fold 30will disappear upon expansion of the tampon 10 within the woman'svagina. By expanding the second portion 34 so that it bridges across thevagina opening, one can see that the tampon 10 is in a much betterposition to absorb the influx of menses and/or blood that may contact itafter it has been inserted into the woman's vagina. It should also berecognized that by extending the length of the resilient member 16around the locations of the first and second folds, 26 and 28respectively, that the tampon 10 can open within the vagina whileretaining a smooth curvature approximate first and second folds, 26 and28 respectively. This smooth curvature at the locations of the first andsecond folds, 26 and 28 respectively, assures that the woman will notexperience any discomfort during use. The presence of the resilientmember 16 is also beneficial in that it does away with any requiredconditioning period wherein the absorbent 12 requires a certain amountof time before it can radially expand outward and intercept anappreciable amount of body fluid. Many prior art tampons are incapableof preventing leakage of body fluid until the absorbent has expanded acertain amount so as to fill the vaginal passage.

Referring to FIG. 8. one can see that upon removal of the tampon 10 fromthe woman's vagina, that the second portion 34 may bow outward as thefirst and second folds, 26 and 28 respectively, are pressed inward bythe interior walls of the woman's vagina. This action is caused bypulling downward on the withdrawal string 38. As the withdrawal string38 is pulled downward, the first and third portions, 32 and 36respectively, are forced inward towards one another. This action willallow the first and second folds, 26 and 28 respectively, to move closertogether and will urge the second portion 34 to bow outward and form anapex 52. As this occurs, the outside diameter of the tampon 10 issignificantly reduced in size and a comfortable removal of the tampon 10is possible. It should be noted that sometimes the second portion 34will fold inward to the configuration shown in FIG. 5 upon removal fromthe vagina. This configuration also allows for a comfortable removal forthe first and third portions, 32 and 36 respectively, are able to movecloser together as the withdrawal string 38 to pulled downward.

Referring now to FIGS. 9 and 10, a tampon applicator 54 is shown whichincludes an outer tube 56 and an inner tube 58. Both of the tubes 56 and58 are hollow and each one can be formed from paper, paper board,cardboard, plastic, thermoplastic film, a combination thereof or fromother known materials. The outer tube 56 and the inner tube 58 can beformed of similar or dissimilar materials, but preferably both areformed from the same material. If paper, paper board or cardboard isused, it can be coated with a wax or water-insoluble polymer to renderit water-resistant. Suitable plastic materials include polyolefins, suchas low density polyethylene and polypropylene. The outer tube 56 shouldhave sufficient strength and rigidity to prevent collapsing under normalvaginal pressures. The outer tube 56 and the inner tube 58 can be formedinto a cylindrical shape having a longitudinal seam or be spirally orconvolutely wound. The outer tube 56 can have a relatively smalldiameter of between from about 10 mm to about 20 mm if desired. Theinner tube 58 should be slightly smaller in diameter than the outer tube56 and is designed to telescopically slide within the inner diameter ofthe outer tube 56.

The applicator 54 also has an insertion tip 60 formed at one end of theouter tube 56 which can contain a plurality of soft and flexible petals62. The petals 62 can be arranged to form a dome-shaped nose. The petals62 can be separated by narrow slots 64. Perforation can be substitutedfor the slots 64 if desired. The slots 64 allow each petal 62 toradially flex or bend outward so as to provide an enlarged openingthrough which the tampon 10 can be expelled as the inner tube 58 ispushed into the outer tube 56. Either an even or an odd number of petals62 can be used, but preferably, there are an odd number of petals 62,such as 3, 5, 7, etc. By using an odd number of petals 62, one canprevent the outer tube 56 from collapsing or flattening after the tampon10 has been expelled. Most preferably, the tampon applicator 54 willcontain five petals 62. By preventing the outer tube 56 from collapsing,one can be assured that the tissues of the woman's vagina will not bepinched when the tampon applicator 54 is inserted into or removed fromthe woman's vagina. For optimum performance, all of the petals 62 shouldhave the same shape and dimension. Each of the petals 62 can have anelongated, approximately truncated shape, with a rounded end and eachcan have a length of about {fraction (7/16)} of an inch (about 11.1 mm).

The tampon applicator 54 is very useful in that it will assure that thecompressed tampon 10 will retain its unique shape until it is insertedinto a woman's vagina. At that time, without the restriction of theouter tube 56, the resilient member 16 will be able to expand outwardtowards its original position such that the first and third portions, 32and 36 respectively, will move outward towards the inner walls of thevagina.

It should be noted that even though the tampon applicator 54 has beenshown as a two-piece applicator, it is possible to use a single tubeapplicator if desired. In a single tube applicator, only the outer tubeis present and the tampon is designed to be expelled therefrom by theuser's finger.

METHOD

The method of forming the catamenial tampon 10 and 10′ will now beexplained with reference to the flow diagrams shown in FIGS. 11 and 12.The method will be discussed knowing that the absorbent 12 need not beat least partially enclosed by the cover 14. The method includes thesteps of assembling the resilient member 16 on the absorbent 12. By “on”is meant that the resilient member 16 is placed adjacent to or over theupper surface of the absorbent 12 such that it is vertically positionedabove or situated on top of the absorbent 12. The resilient member 16can be in physical contact with the absorbent 12 or an intermediatelayer could be inserted therebetween. Preferably, the resilient member16 will be in physical contact with the absorbent 12. The resilientmember 16 and the absorbent 12 will form a structure 15 having a centrallongitudinal axis X—X. By “structure 15” it is meant that the resilientmember 16 and the absorbent 12 can be bonded or joined together or maymerely be contacting one another. Preferably, the two materials aresimply arranged or vertically stacked together. However, the twomaterials 12 and 16 could be secured together by an adhesive, such asglue, or other known attachment means to form a laminate, if desired.

When a cover 14 is being used, the resilient member 16 is placed on theabsorbent 12 such that it is spaced away from the cover 14. In otherwords, the resilient member 16 is positioned on the upper surface of theabsorbent 12 while the cover 14 contacts the bottom surface of theabsorbent 12. The resilient member 16 can be aligned along the centrallongitudinal axis X—X, as is shown in FIG. 1 or the resilient member 16′can be offset away from the central longitudinal axis X—X as is shown inFIG. 3. The resilient member 16 can also be positioned closer to one endof the absorbent 12 if desired, assuming that its overall length is lessthan that of the absorbent 12. However, the resilient member 16 ispreferably spaced an equal distance from the opposite ends of theabsorbent 12.

In FIG. 1, the resilient member 16 is positioned along the centrallongitudinal axis X—X. The absorbent 12, the cover 14 and the resilientmember 16 can be folded in half or rolled up so as to form the softwind18. When the resilient member 16′ is positioned adjacent to alongitudinal edge 17 of the absorbent 12, it makes it easier to roll upthe absorbent 12, the cover 14 and the resilient member 16′ to form thesoftwind 18′. By placing the resilient member 16′ off of the centerlineX—X, the resilient member 16′ can be rolled up with the absorbent 12 andthe cover 14 and will end up being located in the center of the softwind18′.

Again looking at FIGS. 1 and 3, one can see that the absorbent 12 andthe cover 14 both have a first longitudinal edge 17 which is coterminousor contiguous with the two layers, 12 and 14 respectively. In addition,the absorbent 12 and the cover 14 are shown having contiguous edges 19and 21, located adjacent to the opposite ends thereof. Accordingly, theabsorbent 12 and the cover 14 have three coterminous edges 17, 19 and21. Because of this, when the softwind 18 or 18′ are formed, theabsorbent 12 and the cover 14 will be flush with one another at thefirst and second ends, 22 and 24 respectively. Furthermore, the cover 14will have a second longitudinal edge 23 which is aligned parallel withthe first longitudinal edge 17 but which is outward from anotherlongitudinal edge 25 of the absorbent 12. The reason for this is thatwhen the absorbent 12, the cover 14 and the resilient member 16 or 16′are rolled or folded into the softwind 18 or 18′ , the longitudinal edge23 of the cover 14 can overlap upon itself and be bonded thereto. Thisoverlap 20 is shown in FIGS. 2 and 4. It should be noted that it is notnecessary to have edges 17, 19 and 21 be coterminous, nor to requirethat the longitudinal edge 23 of the cover 14 extend beyond the otherlongitudinal edge 25 of the absorbent 12. However, by sizing theabsorbent 12 and the cover 14 as is shown in FIG. 1, it is advantageousto form the softwind 18 or 18′. When the absorbent 12, the cover 14 andthe resilient member 16 or 16′ are rolled up as shown in FIG. 4 to formthe softwind 18′ , the cover 14 will circumferentially enclose theabsorbent 12 and is overlapped upon itself at 20. At the overlap 20, thecover 14 can be bonded to itself by heat, pressure, heat and pressure,adhesive, etc.

As mentioned above, the absorbent 12, the cover 14 and the resilientmember 16 can be formed into the softwind 18, as is shown in FIG. 2. InFIG. 2, the resilient member 16 is shorter in length than the length L₂of the absorbent 12. Because of this length difference, the resilientmember 16 will be spaced apart from the first and second ends, 22 and 24respectively. In addition, in FIG. 2, the softwind 18 is shown beingformed by folding both the absorbent 12 and the cover 14 about theresilient member 16 and then bonding the overlapped portion of the cover20 onto itself. Alternatively, as is shown in FIGS. 3 and 4, theresilient member 16′ can have a length which is equal to the length L₂of the absorbent 12. In this embodiment, the absorbent 12, the cover 14and resilient member 16′ can be rolled into the softwind 18′. It shouldbe noted that although the method has been described with respect tofolding or rolling the absorbent 12, the cover 14 and the resilientmember 16 or 16′ to form the softwind 18 or 18′ , that other means maybe used for forming the softwind 18 or 18′.

The softwind 18 or 18′ are then folded on themselves such that the firstand second ends, 22 and 24 respectively, are aligned adjacent to oneanother and each of the softwinds 18 or 18′ contains at least two folds26 and 28, therebetween. The two folds 26 and 28 divide the softwind 18or 18′ into a first portion 32, a second portion 34 and a third portion36. The first, second and third portions, 32, 34 and 36 respectively,can have an equal length or they can be of different length. Forexample, the second portion 34 can be of a shorter length, an equallength or a greater length than the first and third portions, 32 and 36respectively. Furthermore, it is advantageous to form three folds 26, 28and 30 in each of the softwinds 18 or 18′ which are located between thefirst and second ends, 22 and 24 respectively. The three folds 26, 28and 30 will give the softwinds 18 or 18′ a generally M-shaped profile,see FIG. 5. In the generally M-shaped profile, the first and secondends, 22 and 24 are held adjacent to each other and in physical contactto one another by the withdrawal string 38. After the softwind 18 or 18′has been folded into the generally M-shaped profile, the softwind 18 or18′ can be compressed to form the pledget 44. The compressed pledget 44has an insertion end 46 and a trailing end 48.

Referring to FIG. 11, a flow diagram is depicted showing a method offorming a tampon 10 or 10′. The method includes attaching the withdrawalstring to the softwind 18 or 18′ after it has been compressed into thepledget 44. An aperture 40 is then formed through the trailing end ofthe pledget 44 or 48. The withdrawal string 38 is threaded through theaperture 40 and is looped upon itself to hold it secure to the absorbent12. Once the withdrawal string 38 has been added, the tampon 10 or 10′is complete. The withdrawal string 38 will facilitate removal of thetampon 10 or 10′ from the woman's vagina.

Referring to FIG. 12, another flow diagram is depicted, which shows analternative way to attach the withdrawal string 38. In this method, theaperture 40 is formed through the first and second ends, 22 and 24respectively, of the softwind 18 or 18′. The withdrawal string 38 isthen threaded through the aperture 40 and looped upon itself so as tosecure the withdrawal string 38 to the softwind 18 or 18′. After thewithdrawal string 38 has been added, the softwind 18 or 18′ iscompressed into the pledget 44.

It should be noted that in the above two methods, when the softwind 18or 18′ is compressed into the pledget 44, the insertion end 46 couldcontain more absorbent material than the trailing end 48. Thisadditional absorbent material at the insertion end 46 is advantageous inintercepting fluid flow and preventing premature leakage of body fluidpast the tampon 10 or 10′ immediately after the tampon 10 or 10′ hasbeen inserted into the woman's vagina.

While the invention has been described in conjunction with severalspecific embodiments, it is to be understood that many alternatives,modifications and variations will be apparent to those skilled in theart in light of the aforegoing description. Accordingly, this inventionis intended to embrace all such alternatives, modifications andvariations which fall within the spirit and scope of the appendedclaims.

We claim:
 1. A method of forming a tampon, said method comprising thesteps of: a) forming an absorbent member from an airlaid absorbentsheet; b) placing a resilient member on said absorbent member to form astructure having a central longitudinal axis, said resilient memberbeing aligned along said central longitudinal axis; c) forming saidabsorbent member and said resilient member into an elongated softwindhaving a first end and a second end; d) folding said softwind on itselfsuch that said first and second ends are aligned adjacent to one anotherand said softwind contains at least two folds therebetween; e)compressing said softwind into a pledget having an insertion end and atrailing end; and f) securing a withdrawal string to said pledget toform a tampon, said withdrawal string facilitating removal of saidtampon from a woman's vagina.
 2. A method of forming a tampon, saidmethod comprising the steps of: a) forming an absorbent member from anairlaid absorbent sheet; b) placing said absorbent member on a cover toform a structure having a central longitudinal axis, said cover and saidabsorbent member having at least one contiguous edge; c) placing aresilient member on said structure, said resilient member being alignedalong said central longitudinal axis and being spaced apart from saidcover; d) rolling said cover, absorbent member and resilient member intoan elongated softwind having a first end and a second end; e) foldingsaid softwind on itself such that said first and second ends are alignedadjacent to one another and said softwind contains at least two foldstherebetween; f) compressing said softwind into a pledget having aninsertion end and a trailing end; and g) securing a withdrawal string tosaid pledget to form a tampon, said withdrawal string facilitatingremoval of said tampon from a woman's vagina.
 3. A method of forming atampon, said method comprising the steps of: a) forming an absorbentmember from an airlaid absorbent sheet; b) placing said absorbent memberon a liquid-permeable cover to form a structure having a centrallongitudinal axis, said cover and said absorbent member having at leastone contiguous edge; c) placing a resilient member on said structure,said resilient member being offset from said central longitudinal axisand being spaced apart from said cover; d) forming said cover, absorbentmember and resilient member into an elongated softwind having a firstend and a second end; e) folding said softwind on itself such that saidfirst and second ends are aligned adjacent to one another and saidsoftwind contains three folds therebetween which give it an M-shapedprofile; f) securing a withdrawal string to said softwind, saidwithdrawal string facilitating removal of said tampon from a woman'svagina; and g) compressing said softwind into a tampon.
 4. The method ofclaim 3 wherein an aperture is formed in said first and second ends ofsaid softwind and said withdrawal string is passed through said apertureand looped upon itself to hold said withdrawal string secure thereto. 5.The method of claim 3 wherein said absorbent member has a pair of spacedapart longitudinal edges and said resilient member is placed adjacent toone of said longitudinal edges.
 6. The method of claim 3 wherein saidresilient member has a length equal to that of said absorbent member.